Suspension packaging system and method

ABSTRACT

Disclosed is a method of packaging a curved product with a concave back surface that includes positioning the curved product in contact with a suspension pad that includes a notch on the top and bottom edges then stretch wrapping a stretch film around the curved product and the suspension pad with the wrap received in the first and second notches to secure the curved product to the suspension pad which bends the suspension pad to form a planar curve shape that conforms to the periphery of the back surface of the product and minimizes the distance between the product and the pad and increases the surface contact area between the product and the pad.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.12/117,376 filed May 8, 2008, which is a continuation of U.S.application Ser. No. 10/653,318, filed Sep. 2, 2003, which are bothincorporated by reference in their entirety.

BACKGROUND

The present disclosure relates generally to packaging for shipment ofproducts whose configurations have length and width that are largerelative to depth, and more particularly to packaging such productswhich are made of materials or have construction features which are easyto break or otherwise damage in shipping operations.

Current bulk packaging of windshields for the automotive after-markettrade is predominantly configured to hold twenty-five or morewindshields. Such packaging involves construction of a wooden frame withcorrugated fiberboard attached around the framing, along with severalother packaging components to protect various fragile contact points ofthe individual windshields. A considerable amount of labor is requiredto configure the packaging for use by the manufacturer of the glass. Thecontainers are required to be “pre-erected” and they presentdifficulties in the shipping and storage of empty containers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a windshield package according toone embodiment of the present disclosure.

FIG. 2 is a rear perspective view of the package of FIG. 1.

FIG. 3 is a front view of a pattern for a two-tab corrugated fiberboardblank for a windshield suspension pad according to another embodiment ofthe disclosure.

FIG. 4 is a schematic diagram showing a windshield about to be installedon a fiberboard blank according to the pattern of FIG. 3.

FIG. 5 is a view showing the windshield installed on the blank.

FIG. 6 shows the tabs folded up over the bottom edge of the windshield.

FIG. 7 shows the windshield and pad wrapped with stretch wrap filmsuspending the windshield on the pad and thus forming a windshieldpackage.

FIG. 8 shows a corrugated fiberboard blank for a shipping containerbottom tray according to one aspect of the disclosure.

FIG. 9 shows the blank of FIG. 8 erected to form a bottom tray, and asimilar blank erected to form a top tray or lid of the shippingcontainer to be filled with the windshield packages.

FIG. 10 is a view of the back of a package suspending a windshieldtherein and being carried conveniently by a worker.

FIG. 11 is a top view of a plurality of such packages arranged in anX-shaped configuration in a container bottom tray.

FIG. 12 is a perspective view showing the packages in a shippingcontainer ready for installation of the top.

FIG. 13 shows the container closed and strapped closed.

FIG. 14 is similar to FIG. 13 but with a portion broken out of thecorner to show the pads mounted directly on the floor of the containerand with the bottom notches in the pad oriented for access by thelifting forks of a lift truck.

FIG. 15 is a front perspective view of a cabinet door package preparedaccording to an embodiment of the present disclosure.

FIG. 16 is a front perspective view of a windshield package according toan alternative embodiment.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

For the purpose of promoting an understanding of the principles of thedisclosure, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of thedisclosure is thereby intended, such alterations and furthermodifications in the illustrated device, and such further applicationsof the principles of the disclosure as illustrated therein beingcontemplated as would normally occur to one skilled in the art to whichthe disclosure relates.

Referring now to FIGS. 1 and 2, a package according to one embodiment ofthe present disclosure is shown. It includes a corrugated fiberboard pad11 cut to provide three tabs 12 at the bottom edge 13 and which havebeen turned upward to produce notches 14. Similarly, three notches 16have been provided in the upper edge 17. In these instances, instead offorming tabs at the notches, the material has been completely blankedout of the board.

A curved windshield 18 is mounted to the pad 11 and is secured to thepad by film stretch wrapped around the pad and the windshield as at 19.The wrapping material can be wrapped by machine or by hand, and thepattern can be random as long as there is control of location of thewindshield on the pad so that the entire perimeter 21 of the windshieldis well within the bottom and top edges 13 and 17 of the pad and theside edges 22 and 23 of the pad. The film wrapping through the notchesand around the edge of the windshield at the top and around the tabs atthe bottom is important. It is preferable that the wrapping from top tobottom is performed across the majority of the width of the windshield.While the wrapping from top to bottom notches can be parallel on eitherthe front as shown in FIG. 1, or the back, it is preferable that therebe continuous wrap from notches in the upper edge diagonally to notchesin the lower edge on at least the front or the back and, preferably, onboth the front and back of the package. A combination of this angledwrapping with straight wrapping from top notch to bottom notch and fromportions of the top edge other than notches, to portions of the bottomedge both notched and without notches, is shown on the backside of thepad in FIG. 2. So the stretch wrapping of the windshield is adequate tosuspend the windshield on the pad with all features of the windshieldedges well within the area defined by the perimeter of the pad. Theupturned tabs 12 held in place by the wrapping may assist in supportingthe weight of the windshield during the wrapping and subsequent handlingand transportation.

Referring now to FIG. 3, there is shown a drawing pattern for a die-cutpad 26 of 275 pound (#) double-walled corrugated fiberboard material.Dimensions in inches are shown as an example. In the resulting die-cutpad, the top edge 27 has two notches 28 punched completely out. The sideedges 29 and 31 are straight. The bottom edge 32 is notched at fourplaces to form two tabs 33 and 34 with light score lines such as 36 tofacilitate folding them forward. A hand hole 35 is blanked out of themiddle. The printed outline of the windshield to be suspended on thispad is printed on the pad as shown at 37, 38, 39 and 41. This outlineprovides appropriate guidelines for the placement location of thewindshield on the pad for stretch wrapping. Various other ways forproper product placement can be used. Another example is die cuts toproduces holes, marks or tabs for orientation points. Of course, suchcuts can be provided at the same time that the pad is cut from stock.

Referring now to FIG. 4, the blank 26 is shown ready for mounting thewindshield 42 on it. The windshield is placed on the pad as shown inFIG. 5, and the tabs 33 and 34 are turned upward and forward in thedirection of arrows 43 so that they overlap the front face of thewindshield at the bottom edge as shown in FIG. 6. The score lines suchas 36 on the pad 26 assure that when the tabs are bent forward andupward the windshield will be properly located with its lower edgeoverlying the pattern drawn or otherwise placed on the front of the pad26.

When the windshield has been positioned such that it matches the patternof lines, the stretch wrap film 44 is stretch wrapped around the pad andthe windshield, with the film being wrapped through notches 28 at thetop and around and covering the tabs 33 and 34 at the bottom, securelylocating the windshield on the pad. Stretch wrap is continued as neededor desired around the front of the windshield and the back of the pad.When the amount of stretch wrapping has been completed to provide thedegree of attachment and protection desired, the wrap film can be cut,and the end portion of the film adhered to the portion already wrapped,using the benefit of the cohesive nature of the wrapping film. Ifdesired, the amount of wrap shown on the front of the windshield at FIG.7, can be more than necessary to simply suspend the windshield securelyon the pad, and/or can be spread out the whole width of the windshield,to serve additional useful purposes as will be described later herein.

Referring now to FIG. 16, an alternate embodiment of the presentdisclosure is shown including curved windshield 18 mounted to pad 11 byfilm stretch wrapped around the pad and the windshield as at 19. Thestretch wrapping is spread out over the whole width of windshield 18 andcovers the entire perimeter of windshield 18.

Referring now to FIG. 8, a die-cut blank 46 of double wall 275#corrugated fiberboard or any other appropriate strength material isshown for the bottom “tray” of a shipping container. It has the usualbottom panel 47 with sidewalls 48, end walls 51 and flaps 52 on the endwalls. The sidewalls have holes punched at 53. This blank can be erectedas shown in FIG. 9, gluing or otherwise securing the flaps 52 to thesidewalls in conventional fashion. A top 56 can be made according to thesame form or pattern blank as for the bottom tray, but omitting holes53, and made slightly larger than the bottom tray, to slide down on itin the direction of arrows 57 to close the shipper.

Prior to closing the shipper, it is filled with window packages such asdescribed above with reference to FIGS. 3-7. After wrapping the window,the wrapped window package 45 (FIG. 7) can be picked up and convenientlycarried by the worker standing at either the front of the wrappedwindshield and pad, or at the rear, and inserting a hand in the handhole 35 as shown in FIG. 10, and picking up and carrying the windshieldto the shipper tray 46 and placing the windshield in the tray with thebottom edge 32 of the pad resting on the bottom 47 of the tray. Sincethe windshield is curved, the wrapping with stretch wrap imparts a curveto the pad. Such curve is shown in FIGS. 1, 2, 11 and 12 where the padforms a planar curve that substantially conforms to the periphery of thewindshield's concave back surface. Therefore, the windshields will beplaced in the tray in an “X” configuration as shown in FIGS. 11 and 12.By placing them in this configuration, instead of nesting all windshieldpackages in one orientation, half of them are oriented in one directionand the other half in the other direction. Therefore the convex frontsurfaces of all of the packages face inwardly toward the center plane 61(FIGS. 8 and 11) of the container. The two windshield packages 45L and45R at the center of the container could have their convex front facesin abutting relationship. Therefore, it may be desirable that thewrapping for these two packages be extra thick to prevent any left toright (FIG. 11) shifting of the packages. Alternatively, and more likelythan extra wrapping on center packages, some packing material can beplaced between these facing windshield packages 45L and 45R. An exampleis one double wall panel 50 of corrugated fiberboard. The rest of thepackages nest. The side edges 29 and 31 of the pads are close enough tothe end walls 51 of the tray that there is no shifting sideways of thewindshields within the tray.

Bottom notches 14 were mentioned with reference to the embodiment ofFIGS. 1 and 2. Similarly, there are the bottom notches 30 in the pads ofthe illustrations of the two-notch embodiment of the FIGS. 3-7 and10-14. According to another feature of the disclosure mentioned withreference to FIG. 8, there are four holes 53 in the sidewalls 48 of thebottom tray 46 of the container. As best shown in FIG. 14, the bottomedges 32 of the pads rest on the floor 47 of the tray 46. The top ofeach of the notches 30 is spaced above the tray bottom 47. The holes 53are aligned with the notches in the pads, all of which are aligned intwo rows 35 (FIG. 11) when the containers have been packed with thepackages 45. The holes 53 provide access to the lifting forks 40 of aforklift truck. Thus, it is possible to use the packed containersaccording to the present disclosure, without pallets, because the forksof the lift truck can enter the access holes 53 and pass through notches30 under the windshields and lift the whole shipper and transport it asneeded. The upturned tabs 34, and stretch wrapping around them, provideprotection for the pads and the suspended windshield glasses. If furtherprotection is desired to assure prevention of edge crush of the pads bylifting forks at notches 30, some tubes or downwardly opening channelsmade of corrugated fiberboard or other material can be placed from theaccess holes 53 in one tray wall and extend through the passagewaysformed by the bottom notches 30 of the pads to the access holes in theopposite wall of the tray. An example of such channel is shown in FIG.12 where two such channels 55 are shown partially inserted into the twopassageways 35 (FIG. 11) formed by the two notches 30 each, of all ofthe pads in a filled container bottom tray. This is a way that, ifneeded or desired, additional protection can be provided in the tops ofthe passageways formed by the notches 30 in all of the window packagesfrom one of the walls 48 through the container to the other wall 48.After a container is filled, the lid 56 can be installed and can rest onthe upper edges 27 of the suspension pads and strapped closed by polystrapping 64 in two places, running through the access holes 53, andunder the pads through the notches 30. If desired to preclude any edgecrush by the strapping 64, some tabs 66 of fiberboard or other materialcan be folded around the upper edges of the holes 53 as shown in FIG.13. Similar protection can be provided at other locations such as tabs67.

Packaging according to the present disclosure may be done by performingthe stretch wrapping by hand. But various stretch wrapping machines areknown. Examples are referenced in U.S. Pat. Nos. 6,564,532 and6,550,222, and the references cited therein. Another is the “YellowJacket 110” which is a horizontal stretch wrapping machine by WileyMetal, of Marion Ind., U.S.A. So the product and pad can be stretchwrapped by machine, if desired.

The packaging of automotive window products individually and “collating”a number of the packages into a shipping container can have realadvantages over conventional practices. It allows safer and easierhandling of individual glass components, as the stretch wrapping can beextensive enough, if desired, to cover the entire perimeter of the glassand thereby preclude encounter of any edge of glass by a worker whileloading the packages into a shipping container. Additionally, thecohesive properties of the stretch wrap film, as one-package nestsagainst another, can lend stability to the bulk packs of multiplepackages, by virtually eliminating the tendency of windshields to“shingle”, i.e. slide out of the bottom of current conventionalpackaging. It can also reduce the incidence of damage in transit.

In the foregoing description, the illustrated embodiments show forwardlyand upwardly turned bottom tabs on the pad. The weight and applicationof the product to the pad can have a bearing on whether it is desirableor necessary to use tabs at the bottom or at the top (at the location ofthe notches 28) or both bottom and top, or not at all. If the glass orother product to be suspended to a pad according to the disclosure isrelatively flat, it may be desirable to have notches in the side edgesof the pad as well as in the top and bottom, and stretch wrap filmaround the product, not only in and through the notches in the top andbottom edges, but also in and through notches in the side edges.

It should be understood that the system described herein can be employedusing suspension pad materials other than 350 pound, double walledcorrugated fiberboard. It depends on the nature and weight of theproduct to be suspended. Since the space requirement of the suspendedproduct is usually significantly greater in length and width, than inthickness, it is usually suspended such that the package will be packedon edge in the shipper. Therefore, the fiberboard will be oriented withthe flutes running vertically to provide the needed vertical columnstrength. It is conceivable that a pad with only one facing secured tothe corrugated media, might be sufficient in some applications.

It is also conceivable that the pad be made of material other thancorrugated fiberboard. A plastic or metal might also be used.Desirability and height of stacking containers in warehouses orvehicles, weight and nature of the packaged product, and otherconsiderations could dictate features of pads made of other materials,to provide the necessary column or top-to-bottom stacking strength ofthe pad. For example, if plastic were used, it might be necessary tohave a corrugated component. Another consideration is the condition ofthe surface of the pad material, which is contacted by the product to besuspended. It cannot be abrasive, if abrasion of the product portion incontact would be detrimental to the needed appearance or performance ofthe product. Otherwise, it may be necessary to stretch wrap portions ofthe pad before placing the product on the pad, so that the stretch wrapfilm will protect the pad-engaging portions of the product fromabrasion, and then wrap the product onto the pad. Alternatively, anon-abrasive coating can be provided on the front of the pad where theproduct will contact it.

The thickness of the wrap film used depends on what is necessary to geta snug covering of the product on the pad. Where the product will bemachine-wrapped onto the pad, film selected will be dictated largely byoptimum effectiveness of performance of the wrapping machine.

If, instead of bulk shipping of ten to thirty or more packages, only onepackage is to be shipped, a simple container can be employed. If theproduct is curved, as for a windshield or backlight (back window), thecorners may appear to be more vulnerable than inboard portions of thewindow. Dunnage can be placed in the container if desired so that thecorners of the pad remain properly situated in the corners of thecontainer. The corners of the glass, being well inboard from the cornersof the container, are well protected. If desired, instead of addingdunnage, pad extension panels or “wings” 26W (FIG. 3) can be provided byscoring or creasing the pad at locations 29 and 31. This will allow thepanels to be folded forward at a ninety-degree angle from the plane ofthe face of the pad and extend across the width or short dimension ofthe shipping container. The short dimension will be relatively small, asthe container is containing only one product package. Therefore theextension panels locate the pad in the container not only side-to-side,but also front-to-rear and, with the back of the pad located against theback of the container, and corners of the product touching or near thefront of the pad, the edges and corners of the product are kept awayfrom the front of the container.

In the description above, the packaged product has been made of glass.The packaging described herein is useful for the packaging and shippingof a variety of other products, where the product is three-dimensionalbut the x-axis and y-axis dimensions are significantly greater than thez-axis dimension. Frequently, for various reasons such as, for example,convenience in removal of a certain package from a group, or to avoidwarp, it is preferred to pack, store and ship the products oriented onan edge, like books in a bookcase. In the above examples, theside-to-side (x-axis) and top-to-bottom (y-axis) dimensions aresignificantly greater for the curved windshield than is the maximumdimension on the front-to-back (z-axis) i.e. the distance betweenimaginary parallel planes, one of which touches the most forward pointof the glass and the other of which touches the most backward point ofthe glass.

Another product having such high and wide relative to front-to-reardimensional relationships is shown in FIG. 15. It is a furniture cabinetdoor, with a glass window in it. Although the door without the windowmight not be considered fragile, it is desirable it not be damaged inpackaging or shipping. The disclosed system avoids risk of damage thatcould occur on the bottom edge if the door were resting on that edge. Soreferring to FIG. 15, the pad 71 of corrugated fiberboard has top,bottom, left and right edges 72, 73, 74 and 76, respectively. Each ofthese edges has a notch in it. The cabinet door 77 is suspended on thepad by stretch wrapping stretch wrap film 78 from top to bottom edgenotches and side-to-side edge notches as shown. The wrapping in thefront envelops the door and pad at the front, and crosses in the frontand back in whatever is found most convenient for the wrapping personnelor wrapping machinery used. Since a single continuous length of film 78can be used in this example as in the above-described examples, portionsof the wrap can be at angles between notches as at 78A in front or inback or both, whatever is convenient and sufficient to hold the doorsnugly against the pad and within the perimeter of the pad. In any case,the entire perimeter of the door is within the entire perimeter of thesupport pad, even considering the notch contour as part of the perimeterof the pad. Pad and wrapping technique can be tailored to the particularproduct to be suspended. In any case, the weight of the product is nottransmitted directly from a portion of the product to any portion of thecontainer in which it is shipped. The product is suspended on the pad,and the weight is transmitted through the pad to the container, thusprotecting the product from damage. Of course, the window 79 in the dooris amply protected.

The pad for the package of FIG. 15, with the single notch in each edge,results in a sort of clover shaped pad. Multiple side edge notches andtop and bottom edge notches can be provided if desired for best productsuspension, depending on the nature of the product packaged.

While the disclosure has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly the preferred embodiment has been shown and described and that allchanges and modifications that come within the spirit of the disclosureare desired to be protected. It should be understood that while the useof the word preferable, preferably or preferred in the description aboveindicates that the feature so described may be more desirable, itnonetheless may not be necessary and embodiments lacking the same may becontemplated as within the scope of the disclosure, that scope beingdefined by the claims that follow.

I claim:
 1. A method of packaging a curved product with a concave backsurface, a top surface, a bottom surface, a height, and a width, themethod comprising: positioning the curved product on a suspension padthat includes a front side, a rear side, a top edge, a bottom edge, aleft edge, a right edge, a first notch along the bottom edge and asecond notch along the top edge, wherein the suspension pad is tallerthan the height of the product, wherein a distance between the first andsecond notches is approximately equal to the height of the curvedproduct, wherein the curved product is positioned in contact against thefront side of the suspension pad with the bottom surface in closeproximity to the first notch and with the top surface of the curvedproduct in close proximity to the second notch; stretch wrapping astretch film around the curved product and the suspension pad with thestretch film received in the first and second notches to secure thecurved product to the suspension pad, thereby bending the suspension padto form a planar curve shape that substantially conforms to an entireperiphery of the concave back surface of the curved product therebyminimizing the distance between the concave back surface of the productand the suspension pad and increasing the surface contact area betweenthe concave back surface and the suspension pad and wherein the stretchfilm is a stretchable material that exhibits elastic recovery when usedas stretch film.
 2. The method of claim 1, further comprising: securingthe suspension pad with the curved product secured to the suspension padwith the stretch film in a container such that no portion of the curvedproduct contacts or is directly adjacent to the container.
 3. The methodof claim 2, wherein the suspension pad with the curved product securedto the suspension pad and the container are constructed and arranged sothat the suspension pad with the curved product secured to thesuspension pad can be inserted and removed from the container as anintact unit without damaging the container.
 4. The method of claim 2,wherein the suspension pad with the curved product secured to thesuspension pad and the container are constructed and arranged totransport the suspension pad and the curved product in a verticalorientation.
 5. The method of claim 4, wherein an entire area below thecurved product within the container is free of bracing or supportelements other than the suspension pad.
 6. The method of claim 5,wherein, in the event the container is dropped while containing thecurved product secured to the suspension pad in a vertical orientation,the suspension pad bent in a planar curve permits the curved product toslide along the suspension pad in a vertical direction restrainedprimarily by the stretch wrap and friction between the curved productand the suspension pad, wherein the stretch wrap exhibits elasticrecovery.
 7. The method of claim 5, wherein, when the suspension padbends and forms the planar curve shape that substantially conforms tothe entire periphery of the concave back surface of the curved product,the top edge of the suspension pad bends and forms a continuous curvedshape.
 8. The method of claim 1, further comprising stretch wrapping thestretch film around the curved product and the suspension pad with thestretch film received a third notch along the bottom edge and a fourthnotch along the top edge.
 9. The method of claim 1, wherein the entiretop edge of the suspension pad is substantially free of bends or creasesthat would impair said top edge from curving when said suspension padbends and forms a planar curve.
 10. The method of claim 1, wherein, whenthe suspension pad bends and forms the planar curve shape thatsubstantially conforms to the entire periphery of the concave backsurface of the curved product, the top edge of the suspension pad bendsand forms a continuous curved shape.
 11. The method of claim 10, whereinthe top edge of the suspension pad defines a straight shape before thecurved product is secured on the suspension pad by the stretch wrappingfilm.
 12. The method of claim 1, wherein, after stretch wrapping thestretch film around the curved product and the suspension pad,substantially the entire periphery of the concave back surface of theproduct abuts the suspension pad.
 13. The method of claim 1, furthercomprising manually lifting the curved product secured to the suspensionpad by the stretch film solely by a hand hole in the suspension padpositioned inside of the periphery of the concave back surface of thecurved product.
 14. A packaged curved product with a concave backsurface, a top surface, a bottom surface, a height, and a width, thepackage made a process comprising: positioning the curved product on asuspension pad that includes a front side, a rear side, a top edge, abottom edge, a left edge, a right edge, a first notch along the bottomedge and a second notch along the top edge, wherein the suspension padis taller than the height of the product, wherein a distance between thefirst and second notches is approximately equal to the height of thecurved product, wherein the curved product is positioned in contactagainst the front side of the suspension pad with the bottom surface inclose proximity to the first notch and wherein the top surface of thecurved product in close proximity to the second notch; stretch wrappinga stretch film around the curved product and the suspension pad with thestretch film received in the first and second notches to secure thecurved product to the suspension pad, thereby bending the suspension padto form a planar curve shape that substantially conforms to an entireperiphery of the concave back surface of the curved product therebyminimizing the distance between the concave back surface of the productand the suspension pad and increasing the surface contact area betweenthe concave back surface and the suspension pad, wherein the stretchfilm is a stretchable material that exhibits elastic recovery when usedas stretch film.
 15. The packaged curved product of claim 14, theprocess further comprising: securing the suspension pad with the curvedproduct secured to the suspension pad with the stretch film in acontainer such that no portion of the curved product contacts or isdirectly adjacent to the container.
 16. The packaged curved product ofclaim 15, wherein the suspension pad with the curved product secured tothe suspension pad and the container are constructed and arranged sothat the suspension pad with the curved product secured to thesuspension pad can be inserted and removed from the container as anintact unit without damaging the container.
 17. The packaged curvedproduct of claim 15, wherein an entire area below the curved productwithin the container is free of bracing or support elements other thanthe suspension pad.
 18. The packaged curved product of claim 17,wherein, in the event the container is dropped while containing thecurved product secured to the suspension pad in a vertical orientation,the suspension pad bent in a planar curve permits the curved product toslide along the suspension pad in a vertical direction restrainedprimarily by the stretch wrap and friction between the curved productand the suspension pad, wherein the stretch wrap exhibits elasticrecovery.
 19. The packaged curved product of claim 14, wherein theentire top edge of the suspension pad defines a continuous curved shapewhen the suspension pad forms the planar curve shape that substantiallyconforms to the entire periphery of the concave back surface of thecurved product.
 20. The packaged curved product of claim 14, whereinsubstantially the entire periphery of the concave back surface of theproduct is in contact with the suspension pad after the stretch film isstretch wrapped around the curved product and the suspension pad.